C1500 Full Protouring Chassis Build, Twin Turbo LS Swap

[loudandproud]

Got the exhaust from the turbo to the cab done.

Ended up doing half of the job with a bad bottle of argon. I was getting alot of color and was frustrated thinking i was just doing something wrong. Sure enough... changed the bottle... and I didnt suck anymore. Jeeeshhh.
Welp the exhaust is going to be cerakoted anyway so whatever. Just hoping i dont have too many cracking issues. If I do... Ill redo it in a more robust wall thickness for the first couple feet.

Next up is making my intake tube from the inter cooler to the throttle body.

https://youtu.be/woq4NaPAkrU

[loudandproud]

https://youtu.be/eLjXB6PEgKs



How many of you guys are running cats on your build? I just got wrapped up with welding up a set of midpipes with 100 Cell metallic cats.
I installed cats mainly because I need to pass inspection, but also because I hated smelling gas anytime I drove the truck.

Im not worried about the power... i should have plenty to break almost everything in my driveline lol.

I place the cats a good way back in the exhaust to try to keep them alive.

Who's melted their cats? What power level did they fail at? How far were they from the motor?

[loudandproud]

Mid pipe is in. Shes tucked in there pretty nice. Im happy with it.

I almost currently going back and fixing up the weld on the hot side that were contaminated by the bad weld gas. I ground the welds flushed with a 120 Flap disc, then 320 grit DA, then a 4.5" scotchbrite, then a wool polish pad with black polishing compound. It brought the pipes up to full luster. Then i clean the piss out of the and started to cap the previous weld. LOOKS WAY BETTER. Now i just have to do it to all of it... lol





Next up im finishing the Carbon Fiber intercooler to intake tube.
Then im gonna take with dual 3" mid pipe and merge to a 5" collector. Then it will be a 5" single out the side of the bed.

[loudandproud]

Lots of work going on in multiple work streams.
Intercooler top is welded up. Carbon Fiber intake tube is roughed in.

Just got the machining on the billet intake flange done...

[Bob in St. Louis]

Inspirational!

[ryeguy2006a]

Looks so good. Love the carbon stuff. Curious how you will attach the carbon intake to the aluminum intercooler?

[Motown 454]

Wow looking good! Nice job on the in take tubes.

[TANKMASTERJ]

As everyone else has said the. Carbon fiber rocks. I'm doing carbon fiber vinyl headliner, a classic dash carbon, carbon fiber mirrors, and going to try and wrap a lot of other accessories as your intake tune.
Your project is rockin
Tankmasterj
Jason

[loudandproud]

Got a bunch of stuff in to start working on the dry sump system.
All ex-nascar bits.

These BMRS hoses are super light... Im digging them as well.

New Video is up covering the details.

https://youtu.be/dgU-ZqaOpPQ

[cwylie]

What brand cats did you use?

[Bob in St. Louis]

Tabby?

[loudandproud]

What brand cats did you use?

100 cell xforce cats.

I may have toured a factory for work two years ago and saw those and a much much more expensive brand being made beside each other. One got a polish... the other when through and automated spiral abrading belt.

One is the "cheap brand" , one is the "nice brand and what you should use"
Thats about all my NDAs will probably let me say.

[loudandproud]

I've been doing some CNC programming work for a buddy who recently picked up a really nice Haas VF2.
In return, hes been helping me out with some machine time. I got the billet intercooler flange modeled up, programmed and machined. Turned out great.
Im very pleased.

I then made a thin, threaded sandwich ring that fits inside of the intercooler. This is going to be fixed inside the intercooler and is actually what the flange bolts to. This keeps nuts out of the intake and prevents anything from vibrating loose and into the engine.



After that,

I tried my hand at home anodizing. This was my process:

• Clean part and scrub with degreaser (wear gloves the whole time to not get finger print oils on the surface)
• Soak part in lye bath (lye and distilled water in a bucket) for 3-10 minutes unit surface turns grey (its the aluminum oxide coming off the surface). This is $6 powdered drain cleaner from walmart. This is "de-smutting"
• Rinse (tap water is fine for this and scrub off smut until part is pure white. Should almost rinse off like dust. If its not, it needs to be in the lye longer
• Rinse with distilled water to remove any residual minerals from using tap water (i use a $1 spray bottle from walmart.
• Put clean cathodes into acid bath. Sodium bisulphate or Sulphuric acid (20-30% molar concentration, ratios found online to avoid doing chemistry math lol). Cathodes should be at least double the surface area of the parts being anodized. Apply to negative terminal of power supply (i tried a battery charger but had to break down and buy a $60 power supply because the battery chargers are too smart now and shut off). Suspend part in bath on Aluminum or titanium wire. I recommend titanium wire because the aluminum errodes quickly and as it erodes the current density per surface area sky rockets. Then you charge the postive to the part. Use the 720 Rule calculators online for needed time and amperage. Voltage falls wherever it falls.
• Pull part out after it is anodized and rinse it and nuetralize the acid with baking soda solution in a spray bottle. Then rinse with distilled water again. If you have any remaining acid, it wont take the dye.
• Soak in a dye bath (dye of your choice and distilled water) at 140F. I used Rit dye to practice in a homedepot bucket with a "bucket heater" from amazon. It was like $24 and worked perfect. Soak until you get the desired pigmentation
• Pull out and rinse off excess dye with distilled water.
• Seal the part by boiling in distilled water for 20 minutes. (Again, bucket and same heater from step 7. Hope depot buckets are made of HDPE and can handle the temp of boiling water fine).
• Done

Really happy with how it turned out. I need to finish my PID controlled curing oven and get this stuff baked. Then i will get some Tamco High Solids clear coat and be bonded together.
The metal parts were anodized strictly for electrical isolation from the carbon fiber to prevent galvanic corrosion. They will be cerakoted prior to final bonding.



https://youtu.be/XKvJMWcNunI

[chevyz240]

I am very impressed with the things you do, and that you do thorough research before diving in to the different jobs! Very inspiring!

[loudandproud]

Cranking along on the Dry Sump piping. Got a lot of Suuppppper nice BMRS hoses and im really digging em. Got all the Turbo feeds and drains finished up in stainless hard line and made up a little scavenging manifold for the turbos since they are low mount.




https://www.youtube.com/watch?v=E5BuMDXosFE

[loudandproud]

Got a big ole side exhaust made up for the truck. 5" is overkill for 3" duals... but It'll look good lol.



https://youtu.be/EhHDkQlhPIQ

Screwed up and ordered 409 stainless instead of 304, I was wondering why it was welding so ****ty. Oh hell... its all getting Cerakote and Heatwrap, so it doesnt matter too much.

The "muffler" is a 5" x 9" Long Vibrant race muffler.

[Vimes]

Wow, that's a big exhaust. You're gonna need a screen of some sort over that or you might be launching small critters on startup.

[Bob in St. Louis]

Wow, that's a big exhaust. You're gonna need a screen of some sort over that or you might be launching small critters on startup.

Here kitty kitty......

[Tig]

I'm truly impressed with your fab skills. Everything has turned out better than a lot of fabricators I have worked with in the past 10 years. Nicely done sir. And I love your YT content as well, awesome.

Random question. What remote filter mount is that? Earls?

[loudandproud]

I'm truly impressed with your fab skills. Everything has turned out better than a lot of fabricators I have worked with in the past 10 years. Nicely done sir. And I love your YT content as well, awesome.

Random question. What remote filter mount is that? Earls?

Thank you for the kind words. Ive learned alot in this whole process. Its been very rewarding. Its a CV Products Remote filter mount. I don't think they make em anymore but you can find used Nascar takeoffs on Ebay. Thats where I got mine.